Unit for the production of track elements

ABSTRACT

According to the invention, a unit ( 10 ) is proposed for the production of track elements ( 25 ), which comprises a plurality of clamping devices ( 14 ) arranged one after another in the longitudinal direction of the unit. Provided in the clamping devices ( 14 ), there is in each case a pedestal element ( 16 ), which is fixed to the floor, and a clamping table ( 24 ) which is connected at least indirectly to the pedestal element ( 16 ). A portion of a track element ( 25 ) may be placed on each clamping table ( 24 ). In order to enable the prefabrication of track elements ( 25 ) whereof the curvature, longitudinal profile and camber are individually different, the clamping tables ( 24 ) are positionally adjustable with respect to the particular pedestal element ( 16 ).

The present invention relates to a unit for the production of trackelements.

Tracks, in particular railway tracks and, here, in particular railwaytracks for magnetic-levitation transport systems, are composed ofindividual track elements. In the case of commercially known trackelements for a magnetic-levitation transport system, these are concreteparts which are produced on site. In order to simplify manufacture andreduce the production costs, future track elements will be prefabricatedas metal parts in a factory. These metal parts will then be brought tothe track site and mutually connected there such that the course of thetrack is as continuous as possible, even with different land profiles.The track elements intended for a magnetic-levitation transport-systemproject are for example 62 m long and are arranged above the surface ofthe ground on supports. These track elements are steel components madeof thick-walled steel plate. In cross-section, these track elements havea trapezoidal box-type profile having two upper transverse cross arms inthe installed position, so that an approximately T-shaped cross-sectionis obtained overall.

Although the said track elements are all approximately the same length,they differ in terms of their detail geometry. Amongst other things,this refers for example to an individual bending about a vertical axis(curvature), about a horizontal axis extending transversely to thelongitudinal axis of the track element (longitudinal profile) and aboutan axis extending parallel to its longitudinal axis (twist or camber).These geometrical properties are determined individually for each trackelement, according to the geographical characteristics at the site atwhich the particular track element is to be used in construction.

In spite of the thus relatively complex and individually differentdetail geometry of the individual track elements, a high degree ofprecision is required during production. In the case of the said trackelements, with a track element having an overall length of approximately62 m, a maximum manufacturing tolerance of 1 mm is permitted at thelocation of the joins. So that these demands for high precision can besatisfied, very high demands are likewise placed on the units in whichthe individual track elements are prefabricated. With this, the unitsthemselves, and also the production of the track elements, should be aseconomical as possible. The unit according to the invention which isindicated in claim 1 meets these requirements.

The unit according to the invention is made up of a plurality ofclamping devices, which are arranged one after another in thelongitudinal direction of the unit and have clamping tables. Here, theclamping tables are positionally adjustable such that each clampingtable can be adapted to the individual geometry and position of thatportion of a track element which is to be placed thereon. Thus, a typeof “spherical bed” is created, which reproduces the individual detailgeometry of the particular track element. As a result of theadjustability, it is possible to produce different track elements usingthe same clamping device, as a result of which the cost of the unit, andthe manufacturing costs for the individual track elements, areconsiderably reduced.

Advantageous further developments of the invention are indicated in thesub-claims.

The further development of the invention according to claim 2, providesfor the preferred adjustment directions and pivot axes.

A clamping device according to claim 3 is particularly robust andreliable in operation.

A rapid and reliable pivotal movement of the clamping table of aclamping device of the unit is produced in the further development ofthe invention according to claim 4.

The further development of the invention represented in claim 5 enablessimple vertical adjustment and pivoting of a clamping table.

The adjustment of the position of a clamping table in the lateraldirection, as seen in the longitudinal direction of the unit, is enabledin simple manner as a result of the further development of the inventiondescribed in claim 6.

To obtain defined geometrical ratios at any point during the procedurefor producing a track element, it should be possible to fix theappropriate portion of the track element on a clamping table. Claim 7indicates a way in which this is possible.

In the event of different local geometrical characteristics along thetrack element, the inventive further development according to claim 8increases the universal usability of a clamping device of the unit.

The manner in which the track element is inserted into, and removedfrom, the clamping device is facilitated by the further development ofthe invention indicated in claim 9. It is moreover possible tomanufacture track elements having different widths on a clamping deviceof this type.

Claim 10 indicates a further development of the invention, which enablesreliable and convenient positional adjustment and simple pivoting of theclamping table of a clamping device of the unit according to theinvention.

The position and location in space of a clamping table can be adjustedautomatically as a result of the further development of the inventionaccording to claim 11.

The precision during production of a track element is monitored by thefurther development of the invention claimed in claim 12. This furtherdevelopment is also useful for documentation and quality assurance.

The further development of the invention according to claim 13facilitates assembly and reduces the time required for production of atrack element.

The further development of the invention according to claim 14 isparticularly preferred: In this, the clamping tables are constructedsuch that the track element can be constructed in a head-first position.Here, for assembling a track element on the clamping table of theindividual clamping devices, the upper cover plate of the track element,for example, is placed on first. The lateral and other elements of thetrack element can then be connected to the cover plate and to oneanother for example by spot welding or tack welding. Thus, in the unitaccording to the invention, the track element is constructed in a“head-first” position. The term “head-first” here refers to the futureinstalled position, that is to say that, at the end of the assemblyprocedure, the track element lies on the clamping tables with its futuretop side at the bottom.

An exemplary embodiment of the invention is now explained in detail,with reference to the accompanying drawing, which shows:

FIG. 1: a schematic plan view of a unit for producing track elements,having a plurality of clamping devices;

FIG. 2: a schematic front view of a clamping device from FIG. 1; and

FIG. 3: a schematic side view of the clamping device from FIG. 2.

In FIG. 1, a unit for producing track elements is denoted as a whole bythe reference numeral 10. It includes an elongated cavity 12, which ispresent in the floor portion, is rectangular in plan view and in which atotal of 25 clamping devices 14 are arranged distributed over itslength. The length of the cavity 12 is somewhat greater than the lengthof a track element (not illustrated in FIG. 1). The spacings between theindividual clamping devices 14 are smaller in the centre and in the twoend regions of the unit 10 than in the other regions.

One of the clamping devices 14 is now explained in detail with referenceto FIGS. 2 and 3, it being understood that the individual clampingdevices 14 of the unit 10 can all be realised in identical manner.

The clamping device 14 includes a pedestal element 16, an intermediateelement 22, which is connected to the pedestal element 16 by way of twovertical supporting elements 18, 20, and a clamping table 24 arrangedabove the intermediate element 22. A portion of a track element 25 lieson said clamping table.

The pedestal element 16 includes a base plate 26, which is screwed to afloor plate 28 fixed to the floor. The base plate 26 has a rectangularbasic form and is aligned transversely to the longitudinal direction ofthe unit, which, in FIG. 2, extends perpendicularly to the plane of theFigure. Integrally moulded on the two opposing longitudinal edges whichextend transversely to the longitudinal direction of the unit 10, thereis in each case a vertical lug, 30 and 32 respectively, which are spacedsomewhat from the respective edge and extend in each case over thelength of the base plate 26 (FIG. 3). There are bearing bores 34 and 36in the lug 30. Provided in the bearing lug 32, there are likewisebearing bores which are opposite the bearing bores 34 and 36. However,these are not shown in the Figures and therefore have no referencenumeral. In a manner which will be illustrated in more detail below, thesupporting elements 18 and 20 are mounted in the bearing bores 34 and 36and the bearing bores which are not shown.

In the centre of the base plate 26, a bearing block 40, to which anelectric motor 44 acting on a spindle 42 is joined in pivotal manner, isfixed to the base plate 26. The spindle 42 acts on a threaded block 45which is rotatably fixed to a lug of the supporting element 18. The unitjust described serves for laterally adjusting the position of theclamping table 24, as explained in detail further below. The supportingelements 18 and 20 each include a connecting portion, 46 and 48respectively, and a supporting portion, 50 and 52 respectively. Theconnecting portions 46, 48 and the supporting portions 50, 52 have thesame width in the front view illustrated in FIG. 2. As revealed in FIG.3, as seen from the side, the respective connecting portion 46 and 48 ofthe supporting elements 18 and 20 is however wider than thecorresponding supporting portions 50, 52, and fits between the two lugs30 and 32 of the pedestal element 16 with a slight sliding play.Extending through the respective connecting portions 46 and 48 of thesupporting elements 18 and 20, there is in each case a through bore (notillustrated) through which a respective bearing pin 54 or 56 isintroduced, the ends of said bearing pin in turn being mounted in thebearing bores 34, 36 and the bearing bores (not shown) in the lugs 30,32 of the pedestal element 16. Thus, the supporting elements 18 and 20can pivot or tilt transversely to the longitudinal direction of the unit10, although they are fixed against tilting in the longitudinaldirection of the unit 10.

A piston rod 58, 60 is guided in vertically movable manner in eachsupporting element 18, 20. The upper end of the piston rods 58, 60 isconnected to the intermediate element 22 by way of a cardanic bearing(not illustrated in more detail in the Figure). Part of the cardanicbearing is in each case a pin 62, 64, which engages in a bearing bush66, 68 in the intermediate element 22. The piston rods 58 and 60 may belocked with respect to the corresponding supporting portions 50 and 52in the respectively adjusted position by way of a device which is notshown in FIGS. 2 and 3. The piston rods 58 and 60 and the supportingportions 50 and 52 of the supporting elements 18 and 20 form ahydraulically adjustable device, which serves for adjusting the verticalposition of the clamping table 24.

As can be seen in particular in FIG. 3, an electric motor 68, whichdrives a self-locking threaded spindle 70 extending vertically upwards,is fixed to the right-hand supporting element 20 (as seen in FIG. 2)such that it may pivot about a horizontal axis extending transversely tothe longitudinal direction of the unit. The threaded spindle cooperateswith a threaded block 72, which is in turn fixed to the intermediateelement 22 in articulated manner. The unit comprising the electric motor68, threaded spindle 70 and threaded block 72 is spaced from the pistonrod 60 and the pivot pin clamped by the two cardanic bearings. Thefunction of this unit is to adjust the tilting angle of the clampingtable 24 about an axis which extends transversely to the longitudinaldirection of the unit and substantially horizontally.

The intermediate element 22 is in the form of an elongated andrelatively narrow plate extending transversely to the longitudinaldirection of the unit. It has a central pivot pin 74, which extendsvertically upwards and engages in a bearing bush (not shown in theFigures) in the clamping table 24. Plain bearing rings 76 are arrangedabout the pivot pin 74, between the intermediate element 22 and theclamping table 24. The clamping table 24 furthermore lies on theintermediate element 22 by way of plain bearing pieces 78 arranged alongits lateral edges.

Transversely to the longitudinal direction of the unit, the clampingtable 24 has approximately the same dimensions as the intermediateelement 22, although it has a smaller width, as seen in the longitudinaldirection of the unit. Fixed to underside of the clamping table 24,there is a toothed rail 77 in which a toothed wheel 79 meshes, thislatter being driven by an electric motor (not shown in the Figures)arranged in the intermediate element 22. The clamping table 24 can thusbe pivoted with respect to the intermediate element 22 about thevertical axis produced by the pivot pin 76.

An electric actuating drive 80 is fixed to the left-hand edge of theclamping table 24, as seen in FIG. 2, a rigid holding-down claw 84,which is directed towards the clamping table 24, being fixed to theactuating rod 82 of said actuating drive at the upper end. The actuatingrod 82 may be locked by way of a device which is not illustrated.Arranged at the opposite side, at the edge of the clamping table 24,there are two vertically parallel bearing lugs, of which only the onehaving the reference numeral 86 is shown in the drawing and betweenwhich a holding-down claw 90 is pivotally mounted. The bearing lugs 86form a stop 91 by means of their end faces facing the clamping table 24.A lever portion 92 of the holding-down claw 90, which is remote from theclamping table 24, is connected to the piston rod 94 of a hydrauliccylinder 96. This latter is in turn mounted in articulated manner on thetwo holding lugs 86 and 88. The holding lugs 86 and 88 are connected byway of a rod assembly 98 to a movement device (not shown in the Figure),by means of which it is possible to move the holding lugs 86 and 88, andthus also the holding claw 90, in the lateral direction, as seen in thelongitudinal direction of the unit.

FIG. 2 moreover shows a further control and data collection device 100and a valve block 102. The valve block 102 is hydraulically connected tothe supporting elements 18 and 20 and to the hydraulic cylinder 96 forthe right holding-down claw 90. It is electrically coupled to thecontrol and data collection device 100. This receives signals fromdisplacement sensors 104, 106, 108, 110, 112 and 114 which detect theposition or the stroke of the piston rods or the spindles of thedifferent drives. On the output side, the control and data collectiondevice 100 is furthermore connected to the electric drives 44, 68 and 80and to the drives (not shown) for the horizontal pivoting of theclamping table 24 and the lateral movement of the holding-down claw 96.

The unit 10 is operated in the manner below:

Firstly, the individual adjustment data for each of the 25 clampingdevices 14 stored in a memory of the control and data collection device100 are retrieved for the individual track element 25 to be produced.Then, the supporting elements 18 are controlled by the control and datacollection device 100 such that the piston rods 58 and 60 move into theparticular desired position. Here, the stroke of the piston rods 58 and60 can differ within a clamping device 14, so that the intermediateelement 22, and with it the clamping table 24, are tilted about an axisextending substantially parallel to the longitudinal direction of theunit 10. This takes into account a twist or camber of the track element25 to be produced.

The strokes of the piston rods 58 and 60 can also differ from oneclamping device 14 to another clamping device 14 within the unit 10,according to the desired vertical profile of the particular individualtrack element 25 to be produced in the unit 10.

The electric motor 44 is furthermore controlled by the control and datacollection device 100, such that the threaded block 45 on the spindle 42moves into the desired position. Since this is connected in articulatedmanner to the supporting portion 50 of the supporting element 18 by wayof the lug 43, the supporting element 18 tilts about the pivot axisproduced by the pivot pin 54. As a result, the supporting element 20also tilts in the manner of a parallelogram, thus enabling a change inthe position of the clamping table 14 in a horizontal direction which issubstantially transverse to the longitudinal direction of the unit 10.An undesired change in the height of the clamping table 24, which iseffected as a result, can be compensated by withdrawing the piston rods58, 60 accordingly.

The electric motor driving the toothed wheel 79 is controlled such thatthe clamping table 24 pivots with respect to the intermediate element 22in the desired manner about the vertical axis produced by the pivot pin74. It again applies here that this change in position can be adjustedindividually for each clamping device 14 of the unit 10, so that it ispossible to produce a track element 25 which has a particular curvature.

The electric motor 68 is also controlled in the same way by the controland data collection device 100, so that the intermediate element 22, andwith it the clamping table 24, can be tilted about a horizontal axisextending substantially transversely to the longitudinal direction ofthe unit by way of the threaded spindle 70 and the threaded block 72.This adjustment is also effected individually for each of the clampingdevices 14 of the unit 10, according to the desired vertical profile ofthe track element 25 to be produced.

As a result of the above-mentioned adjustments for the clamping devices14 of the unit 10, an individualised spherical bed is created for eachtrack element 25, said spherical bed corresponding to the individualdetail geometry of the particular track element 25.

When these adjustment operations are completed, the upper cover plate ofthe track element 25 to be produced is placed on the clamping tables 25of the unit 10. It is then possible to laterally adjust the position ofthe stop 91 formed by the lugs 86 by actuating the movement unit actingon the rod 98, thus ensuring that the upper cover plate of the trackelement 25 is positioned precisely. It is now possible to fix forexample lateral parts and other elements of the track element to theupper cover plate and to one another, for example by spot welding. Thisproduces a tack-welded track element 25, standing on its head so tospeak, which can undergo final welding in a subsequent operatingprocedure or even in the unit described.

If required, the electrical actuating drive 80 and the hydrauliccylinder 96 are also controlled by the control and data collectiondevice 100, such that a portion or an element of the track element 25,for example a lateral edge, are clamped against the clamping table 24,thus further increasing the manufacturing precision and the safety ofthe operator during the production procedure.

It is thus possible to construct any number of different track elements25 in a head-first position, i.e. with the top side at the bottom, inthe same unit 10.

It is possible to check the actual adjustments of the differentelectrical or hydraulic actuating elements by means of the displacementsensors 104 to 114, which indicate their current setting to the controland data collection device 100. This is particularly useful forachieving the high level of manufacturing precision desired and due tothe demands for quality assurance.

It goes without saying that, instead of electric or hydraulic actuatingelements, it is also possible to use pneumatic or manual actuatingdevices.

The position assumed by the different actuating elements can take intoaccount the twisting produced when processing the track element inanticipatory manner, so that the twisting is compensated automatically.

1. A unit for the production of track elements, having a plurality ofclamping devices which are arranged one after another in a longitudinaldirection of the unit and each include a pedestal element, which isfixed to a floor, and a clamping table which is connected at leastindirectly to said pedestal element and is constructed such that aportion of a track element may be placed thereon and is positionallyadjustable with respect to the pedestal element, wherein the clampingtable of at least one clamping device is held on an intermediate elementwhich may be moved accordingly with respect to the pedestal element, andwherein the clamping table of at least one clamping device may bepivoted about the substantially vertical third axis with respect to theintermediate element, and wherein the vertical adjustment of theclamping table of at least one clamping device, and also its pivotalmovement, are effected by way of at least two mutually spacedlongitudinal adjustable supporting elements connected to the pedestalelement on the one hand, and at least indirectly to the clamping tableon the other, and wherein a tilting angle of at least one of thesupporting elements may be adjusted with respect to the pedestalelement.
 2. A unit according to claim 1, characterized in that theclamping table of at least one clamping device may be pivoted about atleast one of: a substantially horizontal first axis, extending parallelto the longitudinal axis of the unit; a substantially horizontal secondaxis, extending perpendicularly to the longitudinal axis of the unit,and a substantially vertical third axis, extending perpendicularly tothe longitudinal axis of the unit.
 3. A unit according to claim 1,characterized in that, provided in at least one clamping device, thereis at least one lateral holding-down claw by means of which a portion ofa track element may be clamped against the clamping table.
 4. A unitaccording to claim 3, characterized in that the holding-down claw isvertically displaceable with respect to the clamping table.
 5. A unitaccording to claim 4, characterized in that at least two mutuallyopposing holding-down claims are provided, whereof the mutual spacingmay be varied.
 6. A unit according to claim 1, characterized in that atleast one of hydraulic and electric actuators, preferably electricself-locking spindle drives are provided, which effect appropriatemovements.
 7. A unit according to claim 6, which includes a control unithaving a memory which generates signals by means of which the actuatorsmay be moved into appropriate positions depending on data stored inmemory for a particular track element.
 8. A unit according to claim 7,characterized in that sensors are provided, which detect position of theclamping table and send an appropriate signal to the control unit, whichin turn has a comparator device which compares the detected values withset values stored in the memory, a warning signal being generated if thedetected values and the set values deviate from one another by more thana specified value.
 9. A unit for the production of track elements,having a plurality of clamping devices which are arranged one afteranother in a longitudinal direction of the unit and each include apedestal element, which is fixed to a floor, and a clamping table whichis connected at least indirectly to said pedestal element and isconstructed such that a portion of a track element may be placed thereonand is positionally adjustable with respect to the pedestal element,wherein at least one of hydraulic and electric actuators, preferablyelectric self-locking spindle drives are provided, which effectappropriate movements, and wherein a control unit having a memory whichgenerates signals by means of which the actuators may be moved intoappropriate positions depending on data stored in memory for aparticular track element, and wherein sensors are provided, which detectposition of the clamping table and send an appropriate signal to thecontrol unit, which in turn has a comparator device which compares thedetected values with set values stored in the memory, a warning signalbeing generated if the detected values and the set values deviate fromone another by more than a specified value.
 10. A unit according toclaim 9, characterized in that the clamping table of at least oneclamping device may be pivoted about at least one of: a substantiallyhorizontal first axis, extending parallel to the longitudinal axis ofthe unit; a substantially horizontal second axis, extendingperpendicularly to the longitudinal axis of the unit, and asubstantially vertical third axis, extending perpendicularly to thelongitudinal axis of the unit.
 11. A unit according to claim 9,characterized in that the clamping table of at least one clamping deviceis held on an intermediate element which may be moved accordingly withrespect to the pedestal element.
 12. A unit according to claim 11,characterized in that the clamping table of at least one clamping devicemay be pivoted about the substantially vertical third axis with respectto the intermediate element.
 13. A unit according to claim 12,characterized in that vertical adjustment of the clamping table of atleast one clamping device, and also its pivotal movement, are effectedby way of at least two mutually spaced longitudinal adjustablesupporting elements connected to the pedestal element on the one hand,and at least indirectly to the clamping table on the other.
 14. A unitaccording to claim 13, characterized in that a tilting angle of at leastone of the supporting elements may be adjusted with respect to thepedestal element.
 15. A unit according to claim 9, characterized inthat, provided in at least one clamping device, there is at least onelateral holding-down claw by means of which a portion of a track elementmay be clamped against the clamping table.
 16. A unit according to claim15, characterized in that the holding-down claw is verticallydisplaceable with respect to the clamping table.
 17. A unit according toclaim 16, characterized in that at least two mutually opposingholding-down claims are provided, whereof the mutual spacing may bevaried.
 18. A unit according to claim 9, characterized in that, providedon the clamping table of at least one clamping device, there is at leastone lateral stop against which a portion of the track element may beplaced.
 19. A unit according to claim 9, characterized in that theclamping tables are constructed such that a portion of a track elementmay be placed in a head-first position which is rotated through 180°with respect to a future installed position.